MULTI-LAYER MICRO-WIRE STRUCTURE
A multi-layer micro-wire structure includes a substrate having a surface. A plurality of micro-channels is formed in the substrate. A first material composition is located in a first layer only in each micro-channel and not on the substrate surface. A second material composition different from the first material composition is located in a second layer different from the first layer only in each micro-channel and not on the substrate surface. The first material composition in the first layer and the second material composition in the second layer form an electrically conductive multi-layer micro-wire in each micro-channel.
1 . A multi-layer micro-wire structure, comprising:
a substrate having a surface;
a plurality of micro-channels formed in the substrate;
a first material composition located in a first layer only in each micro-channel and not on the substrate surface;
a second material composition different from the first material composition located in a second layer different from the first layer only in each micro-channel and not on the substrate surface; and
wherein the first material composition in the first layer and the second material composition in the second layer form an electrically conductive multi-layer micro-wire in each micro-channel.
2 . The multi-layer micro-wire structure of claim 1 , wherein the first layer is located farther from the substrate surface than the second layer, the second layer is more electrically conductive than the first layer, and the first layer is more light-absorbing than the second layer.
3 . The multi-layer micro-wire structure of claim 1 , wherein the first layer is located closer to the substrate surface than the second layer, the second layer is more electrically conductive than the first layer, and the first layer is more light-absorbing than the second layer.
4 . The multi-layer micro-wire structure of claim 1 , wherein the first and second layers are in contact over a substantially flat surface.
5 . The multi-layer micro-wire structure of claim 1 , wherein the first and second layers are in contact over a substantially curved surface.
6 . The multi-layer micro-wire structure of claim 5 , wherein the micro-channels have four-sided cross section with a micro-channel top at the substrate surface, a micro-channel bottom opposing the micro-channel top, and micro-channel sides joining the micro-channel top to the micro-channel bottom and wherein the first layer extends from locations on the micro-channel sides that are relatively closer to the micro-channel top to a location that is relatively closer to the micro-channel bottom.
7 . The multi-layer micro-wire structure of claim 1 , wherein the first and second layers are substantially stacked.
8 . The multi-layer micro-wire structure of claim 1 , wherein the first and second layers are at least partially concentric.
9 . The multi-layer micro-wire structure of claim 1 , wherein the first and second layers are electrically conductive.
10 . The multi-layer micro-wire structure of claim 1 , wherein the first layer is more electrically conductive than the second layer or the second layer is more electrically conductive than the first layer.
11 . The multi-layer micro-wire structure of claim 1 , wherein the first or second layers have a variable thickness.
12 . The multi-layer micro-wire structure of claim 1 , wherein the first or second material compositions include carbon black, a dye, or a pigment.
13 . The multi-layer micro-wire structure of claim 1 , wherein the first or second material compositions include metal particles.
14 . The multi-layer micro-wire structure of claim 13 , wherein the metal particles are sintered.
15 . The multi-layer micro-wire structure of claim 13 , wherein the metal is silver or a silver alloy.
16 . The multi-layer micro-wire structure of claim 1 , wherein the second material composition includes a material in the first material composition or wherein the first material composition includes a material in the second material composition.
17 . The multi-layer micro-wire structure of claim 1 , wherein the first material composition includes two different materials in a first ratio and the second material composition includes the same two materials in a second ratio different from the first ratio.
18 . The multi-layer micro-wire structure of claim 1 , further including a third material composition located in a third layer in each micro-channel and not on the substrate surface.
19 . The multi-layer micro-wire structure of claim 18 , wherein the first layer is located farther from the substrate surface than the second layer and the second layer is located farther from the substrate surface than the third layer.
20 . The multi-layer micro-wire structure of claim 18 , wherein the third material composition is substantially the same as the first material composition.
21 . The multi-layer micro-wire structure of claim 18 , wherein the second layer is more electrically conductive than the first and third layers and the first and third layers are more light-absorbing than the second layer.
22 . The multi-layer micro-wire structure of claim 1 , further including a layer located between the first and second layers, the layer including a material that controls the surface energy of the first material composition with respect to the second material composition.
23 . The multi-layer micro-wire structure of claim 1 , wherein the first layer is adhered to the substrate, the second layer is adhered to the substrate, or the first layer is adhered to the second layer.
24 . The multi-layer micro-wire structure of claim 1 , further including an adhesion layer located between the first layer and the substrate or the second layer and the substrate, the adhesion layer promoting adhesion between the first layer and the substrate or the second layer and the substrate.
25 . The multi-layer micro-wire structure of claim 1 , wherein the first layer or the second layer has a color or is reflective.
26 . The multi-layer micro-wire structure of claim 1 , wherein the micro-wire has a width less than a thickness.
27 . The multi-layer micro-wire structure of claim 1 , wherein the micro-wire has a width less than or equal to 10 microns, 5 microns, 4 microns, 3 microns, 2 microns, or 1 micron.
28 . The multi-layer micro-wire structure of claim 1 , wherein the micro-channel has a width less than or equal to 20 microns, 10 microns, 5 microns, 4 microns, 3 microns, 2 microns, or 1 micron.
29 . The multi-layer micro-wire structure of claim 1 , wherein the first or second layer extends from the micro-channel beyond the substrate surface.
30 . The multi-layer micro-wire structure of claim 1 , wherein the first or second layer is solid.
31 . The multi-layer micro-wire structure of claim 1 , wherein the first or second layer is porous.
32 . The multi-layer micro-wire structure of claim 1 , wherein the first layer completely covers the micro-channel surface or the second layer or wherein the second layer completely covers the micro-channel surface or the first layer.
33 . The multi-layer micro-wire structure of claim 1 , wherein the first layer covers only a portion of the micro-channel surface or the second layer or wherein the second layer covers only a portion of the micro-channel surface or the first layer.
34 . The multi-layer micro-wire structure of claim 1 , further including a protective layer located over the micro-wires.
35 . The multi-layer micro-wire structure of claim 34 , wherein the protective layer is also located over the substrate surface.
36 . The multi-layer micro-wire structure of claim 34 , wherein the substrate is substantially transparent and either the first or the second layer is substantially opaque and non-reflective.